Three-dimensionally shaped object forming sheet, three-dimensionally shaped object and production method for same, and production method for decorated three-dimensional object

ABSTRACT

A three-dimensionally shaped object forming sheet includes: a thermally expansive layer distending at a predetermined temperature or higher; a base laminated on one side thereof with the thermally expansive layer; and a photothermal conversion layer for converting absorbed light to heat, formed on at least one side, wherein the base includes a first base and a second base that are laminated; and the first base has an elasticity that is greater than an elasticity of the second base.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.15/993,801, filed on May 31, 2018, which claims priority to JapanesePatent Application No. 2017-145878, filed on Jul. 27, 2017, the entiredisclosure of which is incorporated by reference herein.

FIELD

This application relates generally to a three-dimensionally shapedobject forming sheet that forms a three-dimensionally shaped object, athree-dimensionally shaped object and production method for the same,and a production method for a decorated three-dimensional object.

BACKGROUND

In the related art, a technique for forming a decorative sheet is knownin which a pattern of a microcapsule-containing thermally expansivelayer that distends due to heat is formed on a base, and the pattern ofthe thermally expansive layer is heated and caused to distend (see, forexample, Japanese Patent No. 3954157). Additionally, a technique isknown in which a thermally expandable sheet (also referred to as“thermally foamable sheet) provided on the entire surface of one side ofa base is used to form a convex three-dimensionally shaped object inonly a desired region of this one side. Specifically, first, the patternof the region of the thermally expandable sheet to be made convex isprinted on the surface on the thermally expansive layer side(hereinafter referred to as “front side”) or on the surface on the baseside (hereinafter referred to as “back side”) of the thermallyexpandable sheet using a black ink having high light absorptivity. Next,the side on which the black ink was printed is irradiated with lightsuch as near-infrared light, thereby causing the black ink to generateheat and the thermally expansive layer to distend to a thicknesscorresponding to the gradation of the black ink. Thus, athree-dimensionally shaped object can easily be formed. Moreover,three-dimensional images in which an image pattern and unevenness arecombined can be formed by printing a desired colored image pattern onthe front side of the thermally expandable sheet using cyan, magenta,and yellow colored inks having substantially no light absorptivity (see,for example, Unexamined Japanese Patent Application Kokai PublicationNo. H01-28660). Such a three-dimensional image includes unevennessescorresponding to the image pattern. Additionally, the unevennesses ofthe three-dimensional image can be emphasized depending on the gradationof the color of the image pattern.

The three-dimensionally shaped object described above can be used ininformational media for the visually impaired such as touch maps,pictures in which image patterns and unevennesses are combined,advertising media that seeks to convey visual information more strongly,and the like. Moreover, use of three-dimensionally shaped objects isanticipated for samples that imitate sheet-like materials havingpatterns including unevennesses such as fabric, leather, and wood, andin decorative members such as decorative sheets (decoration sheets,decorative materials) as a substitute for these materials.

Thermally expandable sheets include a non-elastic base having a certainstrength (for example, heavyweight paper) so as to ensure that wrinkles,undulations, and the like do not form when the thermally expansive layerdistends and also ensure that the thermally expandable sheet will betransportable as a printing subject of a printer. Three-dimensionallyshaped objects formed from such thermally expandable sheets can beslightly deformed but cannot be greatly deformed. In particular, whenthree-dimensionally shaped objects formed from such thermally expandablesheets are deformed so as to have a concave surface, wrinkles are likelyto form in the surface. Moreover, three-dimensionally shaped objectsformed from such thermally expandable sheets cannot be deformed so as tohave a three-dimensional curved surface (non-developable surface) suchas a spherical surface. Accordingly, it is difficult to use thisthree-dimensionally shaped object as a substitute for a material havingmicroscopic surface unevennesses, such as leather, to decorate thesurface of an article that has a macroscopic undulating surfaceincluding a three-dimensional curved surface, such as furniture such asa chair.

An objective of the present disclosure is to provide a production methodfor a decorated three-dimensional object in which a macroscopicundulating surface such as a curved surface-shaped portion of an articleis covered with a three-dimensionally shaped object to provide adecoration of microscopic surface unevennesses, a three-dimensionallyshaped object that can be easily deformed into a curved surface of adesired shape, a production method for the three-dimensionally shapedobject, and a three-dimensionally shaped object forming sheet capable offorming the three-dimensionally shaped object.

SUMMARY

In order to solve the problems described above, a three-dimensionallyshaped object forming sheet according to the present disclosureincludes:

-   -   a thermally expansive layer distending at a predetermined        temperature or higher; and    -   a base laminated on one side thereof with the thermally        expansive layer,    -   wherein    -   on at least one side of the three-dimensionally shaped object        forming sheet a photothermal conversion layer for converting        absorbed light to heat is formed,    -   the base comprises a first base and a second base that are        laminated; and    -   the first base has an elasticity that is greater than an        elasticity of the second base.

A three-dimensionally shaped object according to the present disclosureincludes:

-   -   a thermally expansive layer distending at a predetermined        temperature or higher; and    -   a base laminated on one side thereof with the thermally        expansive layer; wherein    -   unevennesses are formed in a surface on one side of the        thermally expansive layer by differences in a distension amount        of the thermally expansive layer;    -   the base comprises a first base and a second base that are        laminated; and    -   the first base has an elasticity that is greater than an        elasticity of the second base.

A production method for the three-dimensionally shaped object accordingto the present disclosure includes:

-   -   a step of providing an electromagnetic wave heat conversion        layer on at least one side of a sheet in which a thermally        expansive layer is provided on a base; and    -   an unevenness forming step of forming unevennesses on a surface        of the sheet by causing the thermally expansive layer of a        region corresponding to the electromagnetic wave heat conversion        layer to distend by irradiating the electromagnetic wave heat        conversion layer with electromagnetic waves of a predetermined        wavelength, wherein    -   the base comprises at least two layers; and    -   the two layers of the at least two layers have elasticities        different from each other.

Another production method for the three-dimensionally shaped objectaccording to the present disclosure is a production method for athree-dimensionally shaped object having unevennesses in a surface, themethod including sequentially performing:

-   -   a base laminating step of producing a base by laminating        together a second base and a first base having greater        elasticity than an elasticity of the second base;    -   a thermally expansive layer forming step of forming, on one side        of the base, a thermally expansive layer that distends at a        predetermined temperature or higher on;    -   a photothermal conversion layer printing step of forming a        photothermal conversion layer for converting absorbed light to        heat and releasing the heat, on at least one surface of a side        of the base and a side of the thermally expansive layer; and    -   a light irradiation step of irradiating light so as to reach the        photothermal conversion layer thereby causing the thermally        expansive layer in a region where the photothermal conversion        layer is formed to distend.

A production method for a decorated three-dimensional object accordingto the present disclosure is a production method for a decoratedthree-dimensional object having unevennesses in at least a portion of asurface, the method including sequentially performing:

a base laminating step for producing a base by laminating a second baseand a first base having higher elasticity than an elasticity of thesecond base;

-   -   a thermally expansive layer forming step of forming, on one side        of the base, a thermally expansive layer that distends at a        predetermined temperature or higher;    -   a photothermal conversion layer printing step of forming a        photothermal conversion layer for converting absorbed light to        heat and releasing the heat, on at least one surface of a side        of the base and a side of the thermally expansive layer; and    -   a light irradiation step of irradiating light so as to reach the        photothermal conversion layer thereby causing the thermally        expansive layer in a region where the photothermal conversion        layer is formed to distend; and    -   an affixing step of affixing another side of the base to a        surface of an article.

Another production method for a decorated three-dimensional objectaccording to the present disclosure includes:

-   -   a step of affixing a sheet-like decorative member, having on one        side therein unevennesses, on a surface of an article having an        undulating surface more macroscopic than the unevennesses;        wherein    -   in the decorative member, at least an affixing side has        elasticity, and the unevennesses that become a decoration are        formed by an electromagnetic wave heat conversion layer        laminated on a thermally expansive layer being irradiated with        electromagnetic waves of a predetermined wavelength.

With the three-dimensionally shaped object forming sheet according tothe present disclosure, it is possible to form a three-dimensionallyshaped object that can be deformed into a desired curved surface. Withthe three-dimensionally shaped object according to the presentdisclosure, it is possible to decorate the surface of a desired article.With the production method for the three-dimensionally shaped objectaccording to the present disclosure, it is possible to manufacture thethree-dimensionally shaped object with good productivity. With theproduction method for the decorated three-dimensional object accordingto the present disclosure, it is possible to manufacture the decoratedthree-dimensional object with good productivity.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of this application can be obtained whenthe following detailed description is considered in conjunction with thefollowing drawings, in which:

FIG. 1 is an appearance view of a three-dimensionally shaped objectaccording to the present disclosure;

FIG. 2A is a plan view schematically illustrating the configuration ofthe three-dimensionally shaped object according to the presentdisclosure;

FIG. 2B is a cross-sectional view schematically illustrating theconfiguration of the three-dimensionally shaped object according toEmbodiment 1 of the present disclosure;

FIG. 2C is a cross-sectional view schematically illustrating theconfiguration of a three-dimensionally shaped object according toEmbodiment 2 of the present disclosure;

FIG. 3A is an appearance view explaining a decorated three-dimensionalobject according to the present disclosure;

FIG. 3B is an appearance view explaining a decorated three-dimensionalobject according to the present disclosure;

FIG. 4 is a cross-sectional view schematically illustrating theconfiguration of a three-dimensionally shaped object forming sheetaccording to Embodiment 1 of the present disclosure;

FIG. 5 is a flowchart illustrating the flow of a production method forthe three-dimensionally shaped object and the decoratedthree-dimensional object according to the present disclosure;

FIG. 6A is a schematic view (cross-sectional view) for explaining a baselaminating step in the production method for the three-dimensionallyshaped object according to Embodiment 1 of the present disclosure;

FIG. 6B is a schematic view (cross-sectional view) for explaining athermally expansive layer forming step and an ink receiving layerforming step in the production method for the three-dimensionally shapedobject according to Embodiment 1 of the present disclosure;

FIG. 6C is a schematic view (cross-sectional view) for explaining aphotothermal conversion layer printing step and an image printing stepin the production method for the three-dimensionally shaped objectaccording to Embodiment 1 of the present disclosure;

FIG. 6D is a schematic view (cross-sectional view) for explaining alight irradiation step in the production method for thethree-dimensionally shaped object according to Embodiment 1 of thepresent disclosure;

FIG. 7A is a cross-sectional view schematically illustrating theconfiguration of a three-dimensionally shaped object forming sheetaccording to Embodiment 2 of the present disclosure;

FIG. 7B is a schematic view (cross-sectional view) for explaining a baselaminating step in the production method for the three-dimensionallyshaped object according to Embodiment 2 of the present disclosure;

FIG. 7C is a schematic view (cross-sectional view) for explaining athermally expansive layer forming step and an ink receiving layerforming step in the production method for the three-dimensionally shapedobject according to Embodiment 2 of the present disclosure;

FIG. 7D is a schematic view (cross-sectional view) for explaining aphotothermal conversion layer printing step in the production method forthe three-dimensionally shaped object according to Embodiment 2 of thepresent disclosure; and

FIG. 7E is a schematic view (cross-sectional view) for explaining animage printing step in the production method for the three-dimensionallyshaped object according to Embodiment 2 of the present disclosure.

DETAILED DESCRIPTION

Hereinafter, embodiments of the present disclosure are described indetail while referencing the drawings. In the following embodiments, athree-dimensionally shaped object is described as an embodiment of thetechnical idea of the present disclosure, but the present disclosure isnot limited thereto. To elucidate the description, some of the sizes,positional relationships, and the like of the constituents illustratedin the drawings have been exaggerated and some of the shapes have beensimplified. In addition, in the following description, constituents andsteps that are identical or substantially identical are assigned thesame reference numerals and descriptions are appropriately foregone.

Embodiment 1: Three-Dimensionally Shaped Object

The configuration of a three-dimensionally shaped object 1 according toEmbodiment 1 of the present disclosure is described while referencingFIG. 1 to FIG. 3B. FIG. 1 is an appearance view of thethree-dimensionally shaped object 1. FIG. 2A is a plan viewschematically illustrating the configuration of the three-dimensionallyshaped object 1. FIG. 2B is a cross-sectional view schematicallyillustrating the configuration of the three-dimensionally shaped object1. FIGS. 3A and 3B are drawings explaining use examples of thethree-dimensionally shaped object 1, and are appearance view ofdecorated three-dimensional objects 8 and 8A. In this application,“three-dimensionally shaped object” means a sheet-like printed objecthaving unevennesses on the surface of one side due to being thicker insome portions than others. Particularly, a three-dimensionally shapedobject that has color on the surface of a side that has unevennesses isappropriately referred to as “2.5D image.” Moreover, in thisapplication, unless otherwise noted, “top” and “bottom” in FIG. 2B andthe other cross-sectional drawings describe the same “top” and “bottom.”

As illustrated in FIG. 1 , a 2.5D image (the three-dimensionally shapedobject) 1 according to Embodiment 1 of the present disclosure is asheet-like flexible member in which an image and unevennessesaccompanying the image are formed on one surface. In the following, thesurface of the 2.5D image 1 on which the unevennesses or theunevennesses and the image is formed is referred to as the “front side”of the 2.5D image 1, and the surface of the side opposite the front sideof the 2.5D image 1 is referred to as the “back side” of the 2.5D image1. In the present embodiment, as illustrated in FIG. 2A and FIG. 2B, adesign of grapes is drawn in the 2.5D image 1. In this design, theglobes of the bunch of grapes are raised high (the thickness is great),the leaves of the bunch of grapes are raised lower than the globes ofthe bunch of grapes, and the background is the lowest and flat. Theoverall shape of the 2.5D image 1 is square, but the shape, the size,and the like of the 2.5D image 1 is appropriately selected depending onpurpose. Furthermore, the 2.5D image 1 has elasticity and, asillustrated in FIG. 1 , deforms into three-dimensional curved shapessuch as spherical surfaces and hyperbolic paraboloidal surfaces. Forexample, the 2.5D image 1 can be affixed to an article B having athree-dimensional curved surface such as that illustrated in FIG. 3A toproduce a decorated three-dimensional object 8. The 2.5D image 1 can beaffixed to the surface of an article of any shape without slack, tears,or the like (details are given later in the description of theproduction method). Examples of the article include household items suchas furniture, containers such as beverage bottles, and packagingmaterials, but are not limited thereto.

As illustrated in FIG. 2B, the 2.5D image 1 according to the presentembodiment includes a first base 21, a thermally expansive layer 3provided on the first base 21 and having unevennesses in the topsurface, an ink receiving layer 4 provided with substantially uniformthickness on the entire surface of the thermally expansive layer 3, anda color layer 6 that is formed on a surface of the ink receiving layer4, namely the front side of the 2.5D image 1, to form an image. In thefollowing, the surface of the first base 21 on which the thermallyexpansive layer 3 is provided is referred to as the “front side” of thefirst base 21, and the surface of the side opposite the front side ofthe first base 21 is referred to as the “back side” of the first base21. The surface of the thermally expansive layer 3 on which the inkreceiving layer 4 is provided (also, in the 2.5D image 1, the topsurface having the unevennesses) is referred to as the “front side” ofthe thermally expansive layer 3, and the surface of the side oppositethe front side of the thermally expansive layer 3 is referred to as the“back side” of the thermally expansive layer 3. The surface of the inkreceiving layer 4 on the thermally expansive layer 3 side is referred toas the “back side” of the ink receiving layer 4, and the surface of theside opposite the back side of the ink receiving layer 4 is referred toas the “front side” of the ink receiving layer 4. The 2.5D image 1includes an adhesive layer 23 on the entire back side, that is, on theentire back side of the first base 21. The 2.5D image 1 is producedusing a three-dimensionally shaped object forming sheet 10 illustratedin FIG. 4 . Note that the unevennesses of the 2.5D image 1 can also beexpressed by being formed in the surface of the thermally expansivelayer 3 side of the 2.5D image 1. The three-dimensionally shaped objectforming sheet 10 is also referred to as a “thermally expandable sheet10.”

Embodiment 1: Thermally Expandable Sheet

The configuration of the thermally expandable sheet 10 used in theformation of the 2.5D image 1 is described below while referencing FIG.4 . FIG. 4 is a cross-sectional view schematically illustrating theconfiguration of the three-dimensionally shaped object forming sheet(the thermally expandable sheet) 10 according to Embodiment 1 of thepresent disclosure. As illustrated in FIG. 4 , the thermally expandablesheet 10 according to the present embodiment includes a base 2 obtainedby laminating a second base 22 on the first base 21, the thermallyexpansive layer 3 provided having a uniform thickness on the entiresurface of the first base 21 side of the base 2, and the ink receivinglayer 4 provided having a uniform thickness on the entire surface of thethermally expansive layer 3. In the following, the top surface of thethermally expandable sheet 10 is referred to as the “front side” of thethermally expandable sheet 10, and the surface of the side opposite thefront side of the thermally expandable sheet 10 is referred to as the“back side” (or the “bottom surface”) of the thermally expandable sheet10. The front sides and the back sides of the first base 21, thethermally expansive layer 3, and the ink receiving layer 4 are the sameas described for the 2.5D image 1. Note that, in some cases, the frontside of the first base 21 is referred to as the front side of the base2. The base 2 includes the adhesive layer 23 between the first base 21and the second base 22. The thermally expandable sheet 10 is an objectto be printed (or object to be processed) in which color inks that formthe color layer 6 are printed on the front side (top surface) and blackink that forms a photothermal conversion layer 5 (see FIG. 6C) isprinted on the back side (bottom surface). It is sufficient that thedimensions of the thermally expandable sheet 10 are greater than orequal to the dimensions of the 2.5D image 1. Moreover, the dimensions ofthe thermally expandable sheet 10 correspond to the printer used to formthe photothermal conversion layer 5 and the color layer 6. For example,the thermally expandable sheet 10 is an A3 paper size.

Base

The base 2 supports the soft thermally expansive layer 3. The base 2imparts enough strength (rigidity) for the thermally expandable sheet 10to function as an object to be printed. The base 2 has strengthsufficient to prevent wrinkles, undulations, and the like from formingin the thermally expandable sheet 10 when the thermally expansive layer3 distends in part. Furthermore, the base 2 has flexibility and heatresistance corresponding to the transport mechanism of the coatingdevice, the printer, and the like used when forming the thermallyexpansive layer 3. In this application, the term “heat resistance”refers to resistance to the heat applied to the constituents of thethermally expandable sheet 10 and the 2.5D image 1 during the productionof the thermally expandable sheet 10 and the 2.5D image 1, andparticularly to resistance to the heat that causes the thermallyexpansive layer 3 to distend. The base 2 has a laminated structureobtained by laminating the second base 22 on the first base 21, on whichthe thermally expansive layer 3 is provided. Furthermore, the base 2includes the adhesive layer 23 between the first base 21 and the secondbase 22. As such, with the base 2, the first base 21 and the second base22 can be peeled from each other. In the following, the surface of thesecond base 22 on the first base 21 side is referred to as the “frontside” of the second base 22, and the surface of the side opposite thefront side of the second base 22 is referred to as the “back side” ofthe second base 22. Note that, in some cases, the back side of thesecond base 22 is referred to as the back side of the base 2. The firstbase 21, the second base 22, and the adhesive layer 23 individually haveheat resistance. It is sufficient that the first base 21, the secondbase 22, and the adhesive layer 23 have the strength described abovewhile laminated (that is, while configured as the base 2). Moreover, asdescribed later, the photothermal conversion layer 5, which releasesheat that causes the thermally expansive layer 3 to distend, is printedon the back side of the thermally expandable sheet 10 (that is, on theback side of the second base 22). Accordingly, it is preferable that thethickness of the base 2 be small while maintaining strength so as tofacilitate the propagation of the heat released by the photothermalconversion layer 5 to the thermally expansive layer 3. Additionally, itis preferable that the first base 21, the second base 22, and theadhesive layer 23 individually have high thermal conductivity.

The elasticity of the first base 21, on which the thermally expansivelayer 3 is provided, is greater than the elasticity of the second base22. In the 2.5D image 1, the first base 21 can stretch together with thethermally expansive layer 3 due to external forces while reinforcing thesoft thermally expansive layer 3. Accordingly, it is preferable that thecoefficient of extension of the first base 21 is substantiallyequivalent to the coefficient of extension of the thermally expansivelayer 3 prior to thermal expansion, or is lower than the coefficient ofexpansion of the thermally expansive layer 3 prior to thermal expansion.Moreover, it is preferable that the coefficient of extension of thefirst base 21 is greater than or equal to the coefficient of extensionof the region in the 2.5D image 1 where the coefficient of extension islowest (the region where the thickness is greatest). Furthermore, it ispreferable that the first base 21 can stretch and contract together withthe thermally expansive layer 3 in the 2.5D image 1. As a result of thefirst base 21 stretching and contracting, not only does the 2.5D image 1stretch due to external forces, but also contracts to return to theshape prior to stretching. As such, it is easier to affix the 2.5D image1 to an article. Moreover, the 2.5D image 1 can be affixed to an articlehaving cushioning properties such as the seat of a chair. It ispreferable that the first base 21 has durability greater than or equalto that of the thermally expansive layer 3. Furthermore, depending onthe use of the 2.5D image 1, it is preferable that the first base 21 haswater resistance. The front side of the first base 21 has highadhesiveness to the thermally expansive layer 3, and the back side ofthe first base 21 has high adhesiveness to the adhesive layer 23. In oneexample, the first base 21 is a resin film and is formed from a resinselected from polyethylene, polypropylene, polyvinyl alcohol, polyvinylchloride, and polyurethane resins, copolymers thereof, and the like. Thefirst base 21 is formed having a thickness whereby the requiredstrength, the required coefficient of extension, and the like can beobtained.

The second base 22 is a member that primarily ensures the strength(rigidity) of the base 2. The second base 22 suppresses the elasticityof the base 2 and the thermally expandable sheet 10 and maintains theshape of the thermally expandable sheet 10 when the thermally expandablesheet 10 is transported by the transport mechanisms (transport rollers,for example) of the printer, the light irradiation device, and the like.Accordingly, it is preferable that the second base 22 be substantiallynon-elastic. Moreover, it is preferable that the second base 22 isformed from a material that allows ink to be printed on the back side.In cases where it is difficult to print ink on the back side of thesecond base 22, an ink receiving layer (not illustrated in the drawings)similar to the ink receiving layer 4 (described later) is provided onthe back side of the second base 22. While configured as the thermallyexpandable sheet 10, the second base 22 is laminated on the first base21 with the adhesive layer 23 disposed therebetween, but the second base22 is removed when producing the 2.5D image 1. The adhesive layer 23remains on the back side of the 2.5D image 1 (see FIG. 2B). Accordingly,the front side of the second base 22 peels from the adhesive layer 23easier than the back side of the first base 21. Specifically, as thesecond base 22, it is possible to use a non-elastic resin film or thelike made from high-quality paper that has been subjected to siliconeresin processing, kraft paper that has been subjected to silicone resinprocessing, polyethylene terephthalate (PET), or the like.

In the base 2, the adhesive layer 23 functions as an adhesive that bondsthe first base 21 to the second base 22. The adhesive layer 23 alsofunctions as an adhesive that bonds the 2.5D image 1 to the article.Accordingly, it is preferable that the adhesive layer 23 is formed froma known adhesive that has characteristics such as adhesive strength andwater resistance that correspond to the first base 21, the article, andthe uses thereof. Furthermore, it is preferable that the adhesive layer23 has strong adhesiveness that prevents the first base 21 from peelingfrom the second base 22 due to the first base 21 conforming to thethermally expansive layer 3 and trying to deform when the thermallyexpansive layer 3 distends in part. Additionally, it is preferable thatthe adhesive layer 23 has sufficient heat resistance.

Note that tack paper can be used as the base 2 that includes the firstbase 21, the second base 22, and the adhesive layer 23. Tack paper iscommercially available and is used for seals that can be stretched bypeeling off the release paper.

Thermally Expansive Layer

The thermally expansive layer 3 forms unevennesses on the front side ofthe 2.5D image 1 by distending in part. For example, the thermallyexpansive layer 3 is a film that is used in known thermally expandablesheets that contains thermally expandable microcapsules and athermoplastic resin as a binder. The thermally expansive layer 3 isformed having a uniform thickness t₀ on the base 2. The thermallyexpandable microcapsules are formed from a thermoplastic resin andcontain a volatile solvent. While dependent on the type of thethermoplastic resin and the type of the volatile solvent, the volatilesolvent vaporizes when the thermally expandable microcapsules are heatedto about 80° C. or higher and, as a result, distend to a size inaccordance with the heating temperature and the heating time. Therefore,the distension of the thermally expandable microcapsules is limited tothe region of the thermally expandable sheet 10 where the thermallyexpansive layer 3 was heated. As a result, the front side of thethermally expansive layer 3, which is not fixed to the base 2, rises,and unevennesses are formed in the front side of the thermally expansivelayer 3, which is not fixed. This partial heating of the thermallyexpansive layer 3 is performed by the photothermal conversion layer 5(see FIG. 6C), which is made from black ink and is formed on the backside of the thermally expandable sheet 10, converting light andreleasing heat. Moreover, as described in the modified examples later,the partial heating of may be performed by a photothermal conversionlayer 5A (see FIG. 2C), which is made from black ink and is formed onthe front side of a thermally expandable sheet 10A, converting light andreleasing heat. The thermally expansive layer 3 may contain a whitepigment such as titanium oxide. By including a white pigment in thethermally expansive layer 3, the base color of the thermally expansivelayer 3 can be made white so that the color layer 6 formed on the frontside of the thermally expansive layer 3 will exhibit a clear appearance.Depending on the appearance of the 2.5D image 1, the thermally expansivelayer 3 may be colored to a desired color by a (carbon black-free)pigment other than black. Furthermore, depending on the use of the 2.5Dimage 1, the thermally expansive layer 3 has water resistance.

The thermally expansive layer 3 distends, for example, to a thicknessthat is, at maximum, about 10-times the thickness prior to distending.The thickness t₀ of the thermally expandable sheet 10 prior todistending, that is, the thickness t₀ in the region (the background orthe like of the design) that does not distend is set in accordance withthe desired height of the highest convexity. The thermally expansivelayer 3 has elasticity prior to distending. Moreover, the thermallyexpansive layer 3 has elasticity in at least the thickness t₀ portionafter distending as the 2.5D image 1. Note that in the distendedthermally expansive layer 3, elasticity tends to be lower in the regionsthat are thicker than the thickness t₀, that is, in the regions wherethe amount of distension is greater.

Ink Receiving Layer

The thermally expansive layer 3 generally is hydrophobic, and ink doesnot readily adhere thereto. As such, the ink receiving layer 4 isprovided to cause the ink of the color layer 6 to adhere. The inkreceiving layer 4 includes porous silica or alumina that absorbs inkinto gaps, a super absorbent polymer that swells to absorb ink, or thelike, and is formed having a thickness of 10 to tens of μm depending onthe material. Moreover, a receiving layer used in typical inkjet printerprinting paper can be used as the ink receiving layer 4.

Photothermal Conversion Layer

As illustrated in FIG. 6C, in the production of the 2.5D image 1, thephotothermal conversion layer 5 is formed as a black pattern on the backside of the thermally expandable sheet 10 except for in the region wherethe thickness of the 2.5D image 1 is the smallest (the thickness t₀region illustrated in FIG. 2B). After the unevennesses have been formedin the front side of the thermally expansive layer 3, the photothermalconversion layer 5 is removed from the thermally expandable sheet 10together with the second base 22 of the base 2. Accordingly, thephotothermal conversion layer 5 is not present in the 2.5D image 1. Thephotothermal conversion layer 5 is a layer that absorbs light of aspecific wavelength region such as near infrared light (wavelength: 780nm to 2.5 μm), converts the absorbed light to heat, and releases theconverted heat. Specifically, the photothermal conversion layer 5 ismade from, for example, typical carbon black-containing black (K) inkused for printing. The temperature of the photothermal conversion layer5 reached due to the released heat depends on the gradation, that is,the density of the carbon black. The thermally expansive layer 3distends in accordance with the temperature of the photothermalconversion layer 5 and forms the unevennesses in the front side.Accordingly, the photothermal conversion layer 5 is printed by grayscale printing and, when viewed from the front side, is printed athigher densities in regions where higher convexities are to be formed.Moreover, the pattern of the photothermal conversion layer 5 is printedon the back side of the thermally expandable sheet 10 and, as such, is amirror image of the unevenness pattern of the 2.5D image 1. Note thatthe photothermal conversion layer 5 is not limited to absorbing lightand may absorb electromagnetic waves containing radio waves, convert theabsorbed electromagnetic waves to heat, and release the converted heat.Accordingly, the photothermal conversion layer 5 can also be describedas an electromagnetic wave heat conversion layer 5. In this application,unless otherwise noted, the term “light” means near-infrared light thatis converted to heat by the carbon black of the photothermal conversionlayer 5.

Returning to the description of the 2.5D image 1, next, the elements ofthe 2.5D image 1 not included in the thermally expandable sheet 10, andthe elements of the 2.5D image 1 that differ from the thermallyexpandable sheet 10 will be described. With the exception of the planarshape, the first base 21 is the same as the thermally expandable sheet10. The ink receiving layer 4 conforms to the deformation of the topsurface of the thermally expansive layer 3 and covers the thermallyexpansive layer 3.

Thermally Expansive Layer

The thermally expansive layer 3 of the 2.5D image 1 is a main element ofthe 2.5D image 1 and is a film in which the thickness differs by regionso as to form the unevennesses on one side (the front side). In thethermally expansive layer 3 of the 2.5D image 1, the thickness of theregion where the unevennesses are smallest, that is, the thinnestregion, is the thickness t₀. The thermally expansive layer 3 hasflexibility and elasticity in the 2.5D image 1 as well. As describedabove, in the thermally expansive layer 3 of the 2.5D image 1,flexibility and elasticity tend to be lower in the regions havinggreater thickness. Accordingly, when producing a decoratedthree-dimensional object 8, it is preferable that the unevenness shapes,the heights of the convexities, the maximum length, and the like bedesigned such that the 2.5D image 1 deforms in accordance with thesurface shape of the article B to which the 2.5D image 1 is to beaffixed.

Color Layer

The color layer 6 is made from typical cyan (C), magenta (M), and yellow(Y) printing-use color inks. The color layer 6 is formed in a desiredimage pattern on the front side of the 2.5D image 1, that is, on the inkreceiving layer 4, by full-color printing, for example. The color layer6 may further contain white ink. Note that black in the color layer 6 isexpressed by blending the three CMY colors, and carbon black-containingblack ink is not used in the color layer 6. Depending on the use of the2.5D image 1, a pigment-based ink, for example, is used to provide thecolor layer 6 with water resistance.

Decorated Three-Dimensional Object

Configurations of decorated three-dimensional objects according to theembodiments of the present disclosure are described while referencingFIG. 3A and FIG. 3B. As illustrated in FIG. 3A, the article B is a winebottle having a typical shape. The 2.5D image 1 is affixed from thespherical shoulder portion onto the cylindrical body portion of thearticle B. The 2.5D image 1 is used as a label for decorating thearticle B. Note that the size of the 2.5D image 1 is not limited tosizes that can be affixed to a portion of the surface of a smallarticle. For example, as illustrated in FIG. 3B, the size of a 2.5Dimage 1C (the shaded region in the drawing) may be a size that can beaffixed to the entire front side (the front sides of the seat and thebackrest) of an article C, which is a backrest-seat integrated chairwherein the seat has a gentle hyperbolic paraboloidal surface.

Production Method for 2.5D Image and Decorated Three-Dimensional ObjectProduction Device for 2.5D Image

Next, a simple description is given of the devices used in theproduction of the thermally expandable sheet and the 2.5D imageaccording to the present disclosure. A coating device that forms thethermally expansive layer 3, prior to distending, on the base 2 is usedin the production of the thermally expandable sheet 10. Furthermore, asnecessary, a known cutting machine is used to cut the thermallyexpandable sheet 10 to desired dimensions. A printer and a lightirradiation device are also used in the production of the 2.5D image 1.The printer prints the photothermal conversion layer 5 and the colorlayer 6 on the thermally expandable sheet 10. The light irradiationdevice irradiates the thermally expandable sheet 10 with near-infraredlight and causes the photothermal conversion layer 5 to release heat,thereby causing the thermally expansive layer 3 to distend.

The coating device is a device that applies coating material to thesheet-like base to form a coating film having a uniform thickness. Aknown device using a bar coater system, a roll coater system, a spraysystem, or the like can be used for the coating device. It is preferablethat the coating device uses a bar coater system suitable for coating ata uniform thickness.

The printer prints the photothermal conversion layer 5 and the colorlayer 6. An off-set printer, an inkjet printer, or other known printeris used depending on the print quality, production model (massproduction, small quantity production), and the like. Moreover, theprinter satisfies specifications corresponding to the dimensions and thethickness of the object to be printed, namely the thermally expandablesheet 10. The printer prints the photothermal conversion layer 5 and thecolor layer 6 by a method in which the thermally expansive layer 3 isnot heated to, or higher than, the expansion starting temperature of thethermally expansive layer 3 (for example, 80° or higher). The printermay be a printer that can separate the inks by use and print thephotothermal conversion layer 5 and the color layer 6 by the samesystem. Moreover, the printing system of the printer that prints thephotothermal conversion layer 5 and the printing system of the printerthat prints the color layer 6 may be different from each other.

The light irradiation device is a device that irradiates thephotothermal conversion layer 5 of the thermally expandable sheet 10with light and causes the photothermal conversion layer 5 to heat thethermally expansive layer 3, thereby causing the thermally expansivelayer 3 to distend. A known device for forming a conventionalthree-dimensionally shaped object using a conventional thermallyexpandable sheet can be used as the light irradiation device. The lightirradiation device satisfies specifications corresponding to thethickness of the object to be irradiated, namely the 2.5D image 1.Specifically, the light irradiation device includes a transportmechanism that transports the sheet-like object to be irradiated, alight source that irradiates light including near-infrared light that isconverted to heat by the photothermal conversion layer 5, a reflectionplate that reflects the light irradiated from the light source, and acooler that cools the device. In one example, the light source is ahalogen lamp. The light source is provided across the entire width ofthe object to be irradiated. In order to efficiently irradiate theobject to be irradiated with the light irradiated from the light source,the reflection plate is formed as a substantially semi-cylindricalcylindrical curved surface and has a mirror face on the inner surface.The reflection plate covers the side opposite to the side of the lightsource facing the object to be irradiated. The cooler is an aircooling-type fan, a water cooling-type radiator, or the like. In oneexample, the cooler is provided in the vicinity of the reflection plate.

Production Method for 2.5D Image

Next, the production method for the 2.5D image 1 according to Embodiment1 will be described while referencing FIG. 5 , FIGS. 6A to 6D and, asappropriate, FIGS. 2A to 2C and FIG. 4 . FIG. 5 is a flowchartillustrating the flow of the production method for thethree-dimensionally shaped object 1. FIG. 6A is a schematic view(cross-sectional view) for explaining a base laminating step in theproduction method for the three-dimensionally shaped object 1. FIG. 6Bis a schematic view (cross-sectional view) for explaining a thermallyexpansive layer forming step and a ink receiving layer forming step inthe production method for the three-dimensionally shaped object 1. FIG.6C is a schematic view (cross-sectional view) for explaining aphotothermal conversion layer printing step and an image printing stepin the production method for the three-dimensionally shaped object 1.FIG. 6D is a schematic view (cross-sectional view) for explaining alight irradiation step in the production method for thethree-dimensionally shaped object 1. As illustrated in FIG. 5 , in theproduction method for the 2.5D image 1 according to the presentembodiment, a thermally expandable sheet production step S10 forproducing the thermally expandable sheet 10, a photothermal conversionlayer printing step S20, an image printing step S30, and a lightirradiation step S40 are sequentially performed. Thereafter, a basepeeling step S52 and an affixing step S53 are sequentially performed.Thus, the decorated three-dimensional object 8 is produced. Asnecessary, a cutting step S51 is performed prior to the affixing stepS53. In the thermally expandable sheet production step S10, a baselaminating step S11, a thermally expansive layer forming step S12, andan ink receiving layer forming step S13 are sequentially performed.Furthermore, as necessary, a cutting step S14 is performed.

In the base laminating step S11, as illustrated in FIG. 6A, a base paper20 of the base 2 is produced. The base paper 20 is the base 2 prior tobeing cut, and, for example, is rolled paper having a size correspondingto the coating device used in the thermally expansive layer forming stepS12 and the ink receiving layer forming step S13. In the base laminatingstep S11, the first base 21 and the second base 22 having the dimensionsof the base paper 20 are bonded to each other using the adhesive layer23.

In the thermally expansive layer forming step S12, the thermallyexpansive layer 3 is formed on the surface of the first base 21 side(the front side of the first base 21) of the base paper 20 (see FIG.6B). First, a slurry is prepared by blending the thermally expandablemicrocapsules, a white pigment, and a thermoplastic resin solution.Next, the prepared slurry is coated on the base paper 20 by the coatingdevice. The coated slurry is dried and, thus, a thermally expansivelayer 3 having the desired thickness t₀ is formed. Note that multiplecoatings are performed as necessary.

In the ink receiving layer forming step S13, as illustrated in FIG. 6B,the ink receiving layer 4 is formed on the thermally expansive layer 3.First, as in the thermally expansive layer forming step S12, a slurry ofthe ingredients of the ink receiving layer 4 is prepared. Next, theprepared slurry is coated on the thermally expansive layer 3 on the basepaper 20 by the coating device. Then, the coated slurry is dried and,thus, an ink receiving layer 4 having a predetermined thickness isformed.

In the cutting step S14, the base paper 20 and the thermally expansivelayer 3 and the ink receiving layer 4 formed on the base paper 20 arecut, thereby obtaining a thermally expandable sheet 10 having dimensionscorresponding to the printer to be used in the photothermal conversionlayer printing step S20 and the image printing step S30 (see FIG. 4 ).

In the photothermal conversion layer printing step S20, as illustratedin FIG. 6C, the photothermal conversion layer 5 is printed using blackink on the back side (the surface of the base 2 side) of the thermallyexpandable sheet 10. In the image printing step S30, as illustrated inFIG. 6C, the color layer 6 is printed using the color inks on the inkreceiving layer 4 of the thermally expandable sheet 10.

In the light irradiation step S40, the surface of the thermallyexpandable sheet 10 on a side where the photothermal conversion layer 5is printed (the back side of the thermally expandable sheet 10) isirradiated with the light. When the irradiated light enters and isabsorbed by the photothermal conversion layer 5, the irradiated light isconverted to heat. The converted heat propagates from the back side tothe front side of the base 2, thereby heating the thermally expansivelayer 3 to a temperature corresponding to the gradation of thephotothermal conversion layer 5. Then, as illustrated in FIG. 6D, thethermally expansive layer 3 distends in accordance with the gradation ofthe photothermal conversion layer 5. The front side of the thermallyexpansive layer 3 rises due to the distension, and unevennesses areformed in the front side of the thermally expansive layer 3. Whiledepending on the material of the thermally expansive layer 3, thetemperature to which the thermally expansive layer 3 is heated is about80° C. or higher, and is preferably distributed across a range of 100 to120° C. in accordance with the gradation of the photothermal conversionlayer 5. The output of the light source, the transport speed of thethermally expandable sheet 10, and the like are set so that light havingthe light quantity that converts to the heat described above enters thephotothermal conversion layer 5.

In the cutting step S51, the thermally expandable sheet 10 (hereinafterreferred to as “release paper-2.5D image 1B”), for which the thermallyexpansive layer 3 has distended as illustrated in FIG. 6D, is cut to adesired shape. For example, in the cutting step S51, the edges where thecolor layer 6 of the release paper-2.5D image 1B is not formed are cutoff. Moreover, depending on the desired shape, the release paper-2.5Dimage 1B can be subjected to cutting by a cutting machine, punching, ormanual processing. Depending on the cutting, the release paper-2.5Dimage 1B can be molded into a shape that does not fit the printer, thelight irradiation device, and the like.

In the base peeling step S52, the second base 22 is peeled from therelease paper-2.5D image 1B and, as a result, the 2.5D image 1illustrated in FIG. 2A and FIG. 2B is obtained.

In the affixing step S53, the 2.5D image 1 is affixed to the surface ofthe desired article by the adhesive layer 23 on the back side. As aresult, the decorated three-dimensional object 8 illustrated in FIG. 3A,for example, is obtained. The 2.5D image 1 has elasticity and, as such,the 2.5D image 1 can be affixed to the article B without slack, tears,or the like by stretching and affixing the 2.5D image 1 to the article Bso as to follow the shape of the surface of the article B. The 2.5Dimage 1 can be affixed to the article B such that air bubbles are nottrapped between the 2.5D image 1 and the article B. For example, the2.5D image 1 can be affixed to the article C illustrated in FIG. 3B by amethod for affixing a decorative sheet to an article in leatherupholstering.

Modified Examples

The cutting step S14 may be performed in each of steps S20, S30, and S40in order to make the dimensions of the thermally expandable sheet 10correspond to the devices (the printer, the light irradiation device,and the like) used in each of steps S20, S30, and S40. Moreover, thecutting step S14 may be performed multiple times. The order in which thephotothermal conversion layer printing step S20 and the image printingstep S30 are performed may be reversed. The cutting step S51 may beperformed after the base peeling step S52 by a method for processing amember having elasticity.

The black pattern, namely the photothermal conversion layer 5, is notpresent in the 2.5D image 1. As such, the color of the color layer 6exhibits a clear appearance. In the 2.5D image 1, the unevennesses areformed in accordance with the pattern of the photothermal conversionlayer 5 and, as such, the unevennesses are formed in the regions wherethe color layer 6 is not provided. However, a configuration is possiblein which the 2.5D image 1 does not include the color layer 6 and thebase color of the thermally expansive layer 3 is used as the appearancecolor. The thermally expandable sheet 10 used in the formation of such a2.5D image 1 need not include the ink receiving layer 4.

As illustrated in FIG. 2C, the photothermal conversion layer 5 may beprinted on the front side of the thermally expandable sheet 10. When thephotothermal conversion layer 5 is formed on the front side of thethermally expandable sheet 10, the heat released by the photothermalconversion layer 5 propagates to the thermally expansive layer 3 withoutpassing through the base 2 and, as such, the thickness of the base 2 canbe increased. Such a 2.5D image 1 includes a photothermal conversionlayer 5 (5A) below the color layer 6 (see FIG. 2C). The configuration ofsuch a three-dimensionally shaped object 1A is described hereinafter inEmbodiment 2.

Embodiment 2: Three-Dimensionally Shaped Object

The 2.5D image (the three-dimensionally shaped object) 1 according toEmbodiment 1 is affixed to the article after the second base 22 has beenremoved from the base 2. However, it is possible to use the 2.5D image 1while the second base 22 is included. Hereinafter, a three-dimensionallyshaped object according to Embodiment 2 of the present disclosure willbe described while referencing FIGS. 2A and 2C and, as appropriate, FIG.1 and FIGS. 3A and 3B. FIG. 2C is a cross-sectional view schematicallyillustrating the configuration of a three-dimensionally shaped object1A. The same reference numerals are assigned to elements that are thesame as in Embodiment 1 (see FIG. 1 to FIG. 6D), and descriptionsthereof are foregone.

The 2.5D image (the three-dimensionally shaped object) 1A according toEmbodiment 2 of the present disclosure is a sheet-like flexible membersimilar to the 2.5D image 1 according to Embodiment 1 illustrated inFIG. 1 . As illustrated in FIGS. 2A and 2C, the image and theunevennesses are formed on the front side of the 2.5D image 1. Theappearance of the front side of the 2.5D image 1A is the same as that ofthe 2.5D image 1. The decorated three-dimensional object 8 illustratedin FIG. 3A and the decorated three-dimensional object 8A illustrated inFIG. 3B can be produced by coating the adhesive on the back side of the2.5D image 1A and affixing the 2.5D image 1A to the articles B and C.Note that the definitions of the front side and the back side of the2.5D image 1A are the same as described for the 2.5D image 1 ofEmbodiment 1.

As illustrated in FIGS. 2A and 2C, the 2.5D image 1A according to thepresent embodiment includes a base 2A, a thermally expansive layer 3provided on a second base 22A (described later) of the base 2A andhaving unevennesses on the top surface, an ink receiving layer 4provided having a substantially uniform thickness on the entire surfaceof the thermally expansive layer 3, a black pattern, namely aphotothermal conversion layer 5A, formed on a surface of the inkreceiving layer 4, and a color layer 6 that is formed on the front sideof the 2.5D image 1A to form an image. In the base 2A, a first base 21Aand the second base 22A are sequentially laminated from the bottom-up.The elasticity of the first base 21A is greater than the elasticity ofthe second base 22A. Accordingly, the 2.5D image 1A is a structure thatincludes the base 2A instead of the first base 21 of the 2.5D image 1illustrated in FIG. 2A, and an additional photothermal conversion layer5A below the color layer 6. In this 2.5D image 1A, the photothermalconversion layer 5A that releases heat is formed on the thin inkreceiving layer 4 and, as such, the heat released from the photothermalconversion layer 5A easily propagates to the thermally expansive layer3. Accordingly, the gradation of the black ink of the photothermalconversion layer 5A is easily reflected in the size to which thethermally expansive layer 3 distends. As a result, the 2.5D image 1A isclearer and can be provided with finer unevennesses.

Embodiment 2: Thermally Expandable Sheet

The configuration of the thermally expandable sheet 10A used in theformation of the 2.5D image 1A is described below while referencing FIG.7A. FIG. 7A is a cross-sectional view schematically illustrating theconfiguration of the three-dimensionally shaped object forming sheet(the thermally expandable sheet) 10A according to Embodiment 2 of thepresent disclosure. As illustrated in FIG. 7A, the thermally expandablesheet 10A according to the present embodiment includes the base 2Aobtained by laminating the second base 22A on the first base 21A, thethermally expansive layer 3 provided having a uniform thickness on theentire surface of the second base 22A side of the base 2A, and the inkreceiving layer 4 provided having a uniform thickness on the entiresurface of the thermally expansive layer 3. The thermally expandablesheet 10A is an object to be printed in which black ink of thephotothermal conversion layer 5 and color inks of the color layer 6 areprinted on the front side (top surface). As with the thermallyexpandable sheet 10 of Embodiment 1, it is sufficient that the size ofthe thermally expandable sheet 10A is greater than or equal to the sizeof the 2.5D image 1A. Moreover, it is sufficient that the size of thethermally expandable sheet 10A corresponds to the printer used to formthe photothermal conversion layer 5A and the color layer 6 of the 2.5Dimage 1A. In the following, the surface of the second base 22A on whichthe thermally expansive layer 3 is provided is referred to as the “frontside” of the second base 22A, and the surface of the side opposite thefront side of the second base 22A is referred to as the “back side” ofthe second base 22A. The surface of the first base 21A facing the secondbase 22A side is referred to as the “front side” of the first base 21A,and the surface of the side opposite the front side of the first base21A is referred to as the “back side” of the first base 21A. Note that,in some cases, the front side of the second base 22A is referred to asthe front side of the base 2A, and the back side of the first base 21Ais referred to as the back side of the base 2A. The definitions of thefront sides and the back sides of the thermally expansive layer 3 andthe ink receiving layer 4 are the same as described for the thermallyexpansive layer 3 and the ink receiving layer 4 of Embodiment 1.

The base 2A has a laminated structure obtained by laminating the secondbase 22A, on which the thermally expansive layer 3 is provided, on thefirst base 21A. The elasticity of the first base 21A is greater than theelasticity of the second base 22A. In the base 2A, contrary to the base2 of Embodiment 1, the thermally expansive layer 3 is provided on thesecond base 22A that has low elasticity. Moreover, for the base 2A, itis sufficient that the first base 21A and the second base 22A closelycontact each other and there is no need for the first base 21A and thesecond base 22A to be peelable off each other. Additionally, the base 2Aneed not propagate the heat released from the photothermal conversionlayer 5. Accordingly, the thickness of the base 2A can be increased tothe extent that the printer, the light irradiation device, and the likeused in the production of the thermally expandable sheet 10A and the2.5D image 1A can handle. The base 2A has flexibility and elasticity inranges adaptable to the coating device, the printer, and the like.Moreover, as with the base 2 of Embodiment 1, the base 2A has strength(rigidity) corresponding to the production of the thermally expandablesheet 10A and the 2.5D image 1A. Accordingly, the thermally expandablesheet 10A including the base 2A can be provided with elasticity and thenecessary strength throughout the entire thermally expandable sheet 10.The strength of the thermally expandable sheet 10A can be increased by,for example, increasing the thickness of the base 2A.

It is preferable that the first base 21A and the second base 22A havedurability greater than or equal to that of the thermally expansivelayer 3. Additionally, depending on the use of the 2.5D image 1A, thefirst base 21A and the second base 22A have water resistance. The backside of the first base 21A that has high elasticity corresponds to theback side of the 2.5D image 1A to be affixed to an article and, as such,the first base 21A can facilitate the affixing of the 2.5D image 1A. Aswith the first base 21 of Embodiment 1, it is preferable that the firstbase 21A can stretch together with the thermally expansive layer 3 dueto external forces. Furthermore, it is preferable that the first base21A can stretch and contract together with the thermally expansive layer3. In cases where it is difficult to obtain the strength (rigidity)necessary to produce the 2.5D image 1A from the second base 22A alone,the first base 21A is also designed to have a certain degree ofstrength. As with the first base 21 of Embodiment 1, the first base 21Ais a resin film. The first base 21A is formed from the same resin usedto form the first base 21. Additionally, the first base 21A is formedhaving a thickness whereby the required strength, coefficient ofextension, and the like can be obtained.

The second base 22A functions as a core that is sandwiched between thefirst base 21A and the thermally expansive layer 3 in the thermallyexpandable sheet 10A and the 2.5D image 1A. The second base 22Areinforces the thermally expansive layer 3. The elasticity of the secondbase 22A is less than the elasticity of the first base 21A.Additionally, the elasticity of the second base 22A is less than theelasticity of the thermally expansive layer 3 prior to distending. It ispreferable that the second base 22A can stretch due to external forcesof a certain degree or greater. In one example, the coefficient ofextension of the second base 22A is configured such that the thermallyexpandable sheet 10A does not deform when the thermally expandable sheet10A is transported by the transport mechanisms of the printer and thelight irradiation device. Additionally, the front side of the secondbase 22A has high adhesiveness to the thermally expansive layer 3. Thesecond base 22A is a resin film having a certain coefficient ofextension that is less than that of the first base 21A. The second base22A is formed from the same resin used to form the first base 21 and isformed such that the desired mechanical characteristics are obtained.Additionally, the thickness of the second base 22A is preferably athickness whereby the 2.5D image 1A can be easily deformed and thewhereby the necessary strength can be obtained together with the firstbase 21A. It is preferable that the thickness of the second base 22A isless than the thickness of the first base 21A.

The thermally expansive layer 3 and the ink receiving layer 4 of thethermally expandable sheet 10A are the same as the thermally expansivelayer 3 and the ink receiving layer 4 of the thermally expandable sheet10 of Embodiment 1. Next, returning to the configuration of the 2.5Dimage 1A, the elements of the thermally expandable sheet 10A notincluded in the thermally expandable sheet 10A, and the elements of thethermally expandable sheet 10A that differ from the thermally expandablesheet 10 will be described. With the exception of the planar shape, thebase 2A is the same as the thermally expandable sheet 10A. The thermallyexpansive layer 3, the ink receiving layer 4, and the color layer 6 arethe same as the thermally expansive layer 3, the ink receiving layer 4,and the color layer 6 of the 2.5D image 1 of Embodiment 1.

Photothermal Conversion Layer

As with the photothermal conversion layer 5 of Embodiment 1, thephotothermal conversion layer 5A is a layer that absorbs light, convertsthe absorbed light to heat, and releases the converted heat. As with thephotothermal conversion layer 5 of Embodiment 1, the photothermalconversion layer 5A is formed from black ink. The pattern of thephotothermal conversion layer 5 in Embodiment 1 is a mirror image of theunevenness pattern of the 2.5D image 1, but the pattern of thephotothermal conversion layer 5A formed on the ink receiving layer 4 isa normal image of the unevenness pattern of the 2.5D image 1A. Moreover,as described above, since the converted heat will easily propagate tothe thermally expansive layer 3, the density of the carbon black in theblack ink of the photothermal conversion layer 5A can be set lower thanthe density of the carbon black in the black ink of the photothermalconversion layer 5 in Embodiment 1. Accordingly, the phenomenon in whichthe black pattern of the photothermal conversion layer 5A is visiblethrough the color layer 6 covering the photothermal conversion layer 5Acan be suppressed.

Production Method for 2.5D Image and Decorated Three-Dimensional ObjectProduction Method for 2.5D Image

The production method for the 2.5D image 1A according to Embodiment 2will be described while referencing FIG. 5 , FIGS. 7B to 7E and, asappropriate, FIGS. 2A and 2C. FIG. 7B is a schematic view(cross-sectional view) for explaining the base laminating step in theproduction method for the three-dimensionally shaped object 1A. FIG. 7Cis a schematic view (cross-sectional view) for explaining the thermallyexpansive layer forming step and the ink receiving layer forming step inthe production method for the three-dimensionally shaped object 1A. FIG.7D is a schematic view (cross-sectional view) for explaining thephotothermal conversion layer printing step in the production method forthe three-dimensionally shaped object 1A. FIG. 7E is a schematic view(cross-sectional view) for explaining the image printing step in theproduction method for the three-dimensionally shaped object 1A. Thedevices used in the production of the 2.5D image 1A according to thepresent embodiment are the same as the devices used in Embodiment 1. Asillustrated in FIG. 5 , in the production method for the 2.5D image 1Aaccording to the present embodiment, as in Embodiment 1, the thermallyexpandable sheet production step S10, the photothermal conversion layerprinting step S20, the image printing step S30, and the lightirradiation step S40 are sequentially performed. Thereafter, asnecessary, the cutting step S51 is performed, and then the affixing stepS53 is performed. Note that, different from Embodiment 1, the basepeeling step S52 is not performed. As in Embodiment 1, in the thermallyexpandable sheet production step S10, the base laminating step S11, thethermally expansive layer forming step S12, and the ink receiving layerforming step S13 are sequentially performed. Thereafter, as necessary,the cutting step S14 is performed. Next, detailed descriptions are givenof the various steps for producing the 2.5D image 1A according toEmbodiment 2, particularly the steps that differ from the steps forproducing the 2.5D image 1 according to Embodiment 1.

In the base laminating step S11, as illustrated in FIG. 7B, a base paper20A of the base 2A is produced. The base paper 20A is the base 2A priorto being cut, and, for example, is rolled paper of a size correspondingto the coating device used in the successive thermally expansive layerforming step S12 and ink receiving layer forming step S13. In the baselaminating step S11, the first base 21A and the second base 22A havingthe dimensions of the base paper 20A are bonded to each other bythermo-compression bonding.

In the thermally expansive layer forming step S12 and the ink receivinglayer forming step S13, as illustrated in FIG. 7C, the thermallyexpansive layer 3 and the ink receiving layer 4 are successively formedon the surface of the second base 22A side of the base paper 20A (thefront side of the second base 22A). Next, in the cutting step S14, thebase paper 20A on which the thermally expansive layer 3 and the inkreceiving layer 4 are formed is cut. Thus, the thermally expandablesheet 10A is obtained (see FIG. 7A). These steps S12, S13, and S14 arethe same as the steps S12, S13, and S14 of Embodiment 1.

In the photothermal conversion layer printing step S20, as illustratedin FIG. 7D, the photothermal conversion layer 5A is printed using theblack ink on the ink receiving layer 4 provided on the front side of thethermally expandable sheet 10. Next, in the image printing step S30, asillustrated in FIG. 7E, the color layer 6 is printed using the colorinks on the ink receiving layer 4 and on the photothermal conversionlayer 5A provided on the front side of the thermally expandable sheet10A.

In the light irradiation step S40, the surface of the side of thethermally expandable sheet 10A on which the photothermal conversionlayer 5A is printed is irradiated with light. Aside from the surfacethat is irradiated with light, the light irradiation step S40 of thepresent embodiment is the same as the light irradiation step S40 ofEmbodiment 1. As a result of being irradiated with the light, thethermally expansive layer 3 is heated to a temperature corresponding tothe gradation of the photothermal conversion layer 5A. Then, asillustrated in FIG. 2C, the front side of the thermally expansive layer3 rises and the unevennesses are formed in the front side of thethermally expansive layer 3. Next, as in Embodiment 1, the cutting stepS51 is performed and, thus, the 2.5D image 1A illustrated in FIGS. 2Aand 2C is obtained.

In the affixing step S53, an adhesive is coated on one or both of theback side of the 2.5D image 1A (the back side of the first base 21A) andthe region of the surface of the article B where the 2.5D image 1A is tobe affixed. Then, the 2.5D image 1A is affixed to the article B and,thus, the decorated three-dimensional object 8 illustrated in FIG. 3 isobtained. The adhesive is a known adhesive that corresponds to thematerials of the article B and the first base 21A, and has adhesivestrength, water resistance, and other characteristics that correspond tothe use of the article B. The elasticity of the second base 22Apositioned between the first base 21A and the thermally expansive layer3 is lower than the elasticities of the first base 21A and the thermallyexpansive layer 3. As such, it is preferable that the 2.5D image 1A isdeformed, with the second base 22A as the core (axis), along the surfaceshape of the article B such that one of the thermally expansive layer 3and the first base 21A stretches and the other contracts. Moreover, aswith the 2.5D image 1 of Embodiment 1, the 2.5D image 1A can also beaffixed to an article C such as that illustrated in FIG. 3B.

Modified Examples

In the 2.5D image 1A, a concealing layer (not illustrated in thedrawings) may be formed between the photothermal conversion layer 5A andthe color layer 6 using white ink or the like. Alternatively, theconcealing layer may be provided on the photothermal conversion layer5A. Moreover, the concealing layer may be provided below the color layer6. Further yet, the concealing layer may be provided on the entiresurface of the 2.5D image 1A, on the photothermal conversion layer 5Aand on the thermally expansive layer 3. The black photothermalconversion layer 5 is concealed by the concealing layer. As a result,the color layer 6 exhibits a clearer appearance. Particularly, when thecolor layer 6 exhibits pale color, it is preferable that the concealinglayer be provided in the 2.5D image 1. The concealing layer is providedby printing using white ink or the like after the photothermalconversion layer printing step S20 but before the image printing stepS30.

The elasticity of the thermally expandable sheet 10A (particularly thebase 2A) described above is suppressed so that the thermally expandablesheet 10 has strength (rigidity) corresponding to the transportmechanisms of the devices used in the production of the 2.5D image 1A.Increasing the elasticity of the thermally expandable sheet 10A makes itpossible to obtain a 2.5D image 1A that can be easily affixed to anarticle having a curved surface with high curvature. Such a thermallyexpandable sheet 10A is produced by an apparatus wherein the printer,the light irradiation device, and the like do not include transportmechanisms for the object to the processed (the thermally expandablesheet 10A). For example, a printer, such as a screen printer, is used inwhich the object to be processed is fixed to a mounting stand and thenthe object to be processed is printed on. In such a printer, the objectto be processed can be moved while fixed to the mounting stand.Moreover, the printer may print on the object to be processed by movingthe print head without moving the mounting stand to which the object tobe processed is fixed. In one example, the thermally expandable sheet10A is fixed to the mounting stand by the edges of two or four opposingedges of the thermally expandable sheet 10. It is sufficient that thethermally expandable sheet 10A is fixed such that the center portionthereof does not lift from the mounting stand. For example, thethermally expandable sheet 10A may be fixed by an electrostaticadsorption mechanism provided in the mounting stand of the lightirradiation device.

As described above, according to the present disclosure, athree-dimensionally shaped object having flexibility and elasticity andthat can be affixed to a curved surface of a desired shape can be easilyobtained. According to the present disclosure, it is possible to producean article having a macroscopic three-dimensional shape (for example, amacroscopic undulating surface) as a member to be decorated, separatelyproduce a sheet-like three-dimensionally shaped object havingmicroscopic surface unevennesses as a decorative member, and affix thesheet-like three-dimensionally shaped object as the decorative member tothe article as the member to be decorated. As a result, fine decorationscan be easily applied to large articles. The decorative members, namelythe 2.5D images 1 and 1A, are produced from the thermally expandablesheets 10 and 10A that include thermally expansive layers. Theunevennesses of the 2.5D images 1 and 1A (that is, the microscopicsurface unevennesses functioning as decoration) are formed by thephotothermal conversion layer (electromagnetic wave heat conversionlayer) 5 being irradiated with light (electromagnetic waves) of apredetermined wavelength. Therefore, according to the presentdisclosure, microscopic surface unevennesses can be collectively formedwith high precision in a wide region. Additionally, according to thepresent disclosure, the production throughput of the decorative members(the 2.5D images 1 and 1A) can be improved. Furthermore, the elasticityof the decorative members (the 2.5D images 1 and 1A) is high and, assuch, the decorative members can be affixed so as to follow the surfacesof articles having macroscopically three-dimensional shapes.

The uses of the three-dimensionally shaped objects (the 2.5D images) 1and 1A are not limited to decorative members. Since the distendedportion of the thermally expansive layer 3 has elasticity, thethree-dimensionally shaped objects 1 and 1A can be used as sheet-likecushioning materials such as foamed sheets, air cushions, and the like.Moreover, a 2.5D image 1 (1A) that exhibits predetermined shapes,characters, and the like using the unevennesses and that is colored bythe color layer 6 can be used as both a cushioning material and aspackaging material such as packaging paper. Additionally, the thermallyexpansive layer 3 melts when heated to the temperature at which themicrocapsules distend or higher. As such, the 2.5D images 1 and 1A canstacked and thermo-compressed to be formed into a bag shape or the likeand used. Furthermore, the three-dimensionally shaped objects 1 and 1Aare easily formed into a desired uneven shapes and, as such, can be usedas a cushioning material of an electronic circuit board having fine,complex unevennesses. With the three-dimensionally shaped objects 1 and1A used as the cushioning material of an electronic circuit board, theunevennesses are formed for each model number of electronic circuitboard, corresponding to the sizes and the positions of the electroniccomponents mounted on the board, so as to fit together with theelectronic components. Note that both the 2.5D image 1 that does notinclude the photothermal conversion layer 5A (see FIG. 2B) and the 2.5Dimage 1A that does include the photothermal conversion layer 5A (seeFIG. 2C) can be used as a cushioning material of an electronic circuitboard. When the 2.5D image 1A that includes the photothermal conversionlayer 5A is used as a cushioning material of an electronic circuitboard, the 2.5D image 1A may be imparted with electrical conductivity bythe carbon black contained in the black ink. Moreover, a configurationis possible in which the color layer 6 is not formed in thethree-dimensionally shaped objects 1 and 1A used as cushioningmaterials. The model number of the electronic circuit board to beprotected, alignment markers for the electronic circuit board, and thelike may be printed by the color layer 6 on the three-dimensionallyshaped objects 1 and 1A used as cushioning materials. Moreover, sincethe distended thermally expansive layer 3 functions as a heat insulatingmaterial, the three-dimensionally shaped objects 1 and 1A can beattached to walls, windows and other building materials and used as heatinsulating material. The three-dimensionally shaped objects 1 and 1Aused as heat insulating material can easily be attached to constructionmaterials without gaps by, for example, forming unevennesses that matchthe steps of a window frame. The three-dimensionally shaped objects 1and 1A can be used both as heat insulation material and as decorationsuch as wall paper. For example, the three-dimensionally shaped objects1 and 1A form wood grain, tile-like, or similar patterns depending onthe combination of the unevennesses and the color layer 6.

The foregoing describes some example embodiments for explanatorypurposes. Although the foregoing discussion has presented specificembodiments, persons skilled in the art will recognize that changes maybe made in form and detail without departing from the broader spirit andscope of the invention. Accordingly, the specification and drawings areto be regarded in an illustrative rather than a restrictive sense. Thisdetailed description, therefore, is not to be taken in a limiting sense,and the scope of the invention is defined only by the included claims,along with the full range of equivalents to which such claims areentitled.

What is claimed is:
 1. A production method for a three-dimensionallyshaped object, comprising: a step of producing a sheet by providing athermally expansive layer on a main surface of a base on a side of afirst base, the base including the first base and a second base that arelaminated thereon; a step of providing an electromagnetic wave heatconversion layer on a main surface of the base of the sheet on a side ofthe second base; and an unevenness forming step of forming unevennesseson a surface of the sheet by causing the thermally expansive layer of aregion corresponding to the electromagnetic wave heat conversion layerto distend by irradiating the electromagnetic wave heat conversion layerwith electromagnetic waves of a predetermined wavelength, wherein thefirst base and the second base have elasticities different from eachother.
 2. The production method for a three-dimensionally shaped objectaccording to claim 1, wherein an elasticity of the first base is greaterthan an elasticity of the second base; and wherein the first base is aresin film comprising a polyethylene resin, a polypropylene resin, apolyvinyl alcohol resin, a polyvinyl chloride resin, or a polyurethaneresin.
 3. A production method for a three-dimensionally shaped objecthaving unevennesses in a surface, the production method comprisingsequentially performing: a base laminating step of producing a base bylaminating together a second base and a first base having a greaterelasticity than an elasticity of the second base; a thermally expansivelayer forming step of forming, on a main surface of the base on a sideof the first base, a thermally expansive layer that distends at apredetermined temperature or higher; a photothermal conversion layerprinting step of printing a photothermal conversion layer for convertingabsorbed light to heat and releasing the heat on a main surface of thebase on a side of the second base; and a light irradiation step ofirradiating light so as to reach the photothermal conversion layerthereby causing the thermally expansive layer in a region where thephotothermal conversion layer is formed to distend.
 4. A productionmethod for a decorated three-dimensional object having unevennesses inat least a portion of a surface, the production method comprisingsequentially performing: a base laminating step for producing a base bylaminating a second base and a first base having a greater elasticitythan an elasticity of the second base; a thermally expansive layerforming step of forming, on a main surface of the base on a side of thefirst base, a thermally expansive layer that distends at a predeterminedtemperature or higher; a photothermal conversion layer printing step ofprinting a photothermal conversion layer for converting absorbed lightto heat and releasing the heat on a main surface of the base on a sideof the second base; a light irradiation step of irradiating light fromthe side of the second base of the base so as to reach the photothermalconversion layer thereby causing the thermally expansive layer in aregion where the photothermal conversion layer is formed to distend; andan affixing step of affixing the base to a surface of an article.
 5. Theproduction method for a decorated three-dimensional object according toclaim 4, wherein prior to the affixing step, a base peeling step ofpeeling and removing the second base from the first base is performed,and wherein, in the affixing step, the first base is affixed to thesurface of the article.
 6. The production method for a decoratedthree-dimensional object according to claim 5, wherein the first base isa resin film comprising a polyethylene resin, a polypropylene resin, apolyvinyl alcohol resin, a polyvinyl chloride resin, or a polyurethaneresin.
 7. The production method for a three-dimensionally shaped objectaccording to claim 1, wherein a thickness of the second base in adirection from a first side facing the first base toward a second sideopposite to the first side is selected to transmit the heat emitted bythe electromagnetic wave heat conversion layer from the second side ofthe second base to the thermally expansive layer to cause the thermallyexpansive layer to distend at the predetermined temperature or higher,and wherein the second base is configured to be peelable from firstbase.